D4BH (2.

5 TCI) Diesel Engine

(COVEC – F)
Contents 2

 Specification
 General
 System Layout
 Control Logic
 Components Description
 Engine Control Module
 Troubleshooting
 Injection Timing Adjustment
Specification 3

Item Description

Engine Model D4BH (TCI)

No. of Cylinders 4, In-Line

Valve Mechanism OHC

Total Displacement 2,467 cc

Bore X Stroke 91.1 X 95 mm

Compression Ratio 21

Compression Pressure 19.2 kg/㎠

Valve Clearance Intake : 0.15 mm

Exhaust : 0.15 mm

Maximum Power 94 ps

Maximum Torque 22.3 kg.m

Basic Injection Timing ATDC 9º
General 4

Features
Improved Torque Performance

COVEC-F

Torque
Conventional injection pump

50 100

Accelerator position (%)

General 5

Decreased Smoke at Acceleration

Conventional injection pump

Injection
quantity
Excess fuel at
acceleration

COVEC-F

Accelerator position
General 6

Increased Comfort

Conventional type

Control sleeve Fixed

position

COVEC-F

Control sleeve Individual control

position
System Layout 7

Fuel System
Return Pipe

Fuel Tank
Over
Flow
Valve

Nozzle

Fuel Filter & Glow

Sedimenter Plug

Injection Pump
System Layout 8

Components Battery Voltage

Connection
Add. Vehicle Control

Vehicle Sensors

Vehicle Switches

Np Sensor
GE Actuator Fuel Temp. Sensor

Compensation
Resister CSP Sensor
Np Sensor

TCV

TPS
System Layout 9

Input Control Output Control Item

Injection Pump Injection Pump

Np Sensor

CSP Sensor GE Actuator Fuel Quantity

Fuel Temp. Sensor

Compensation Resister Timer Control Valve Injection Timing

TPS

ECU
Vehicle
Vehicle
Sensors
EGR Valve EGR Control
Switches Glow Plugs Glow Control

Diagnostic Lamp Self Diagnosis

Battery Voltage
Control Logic 10

Injection Amount Controls

Example
Np Sensor when CPS is failed
CPS
Pump speed
Eng. speed
3,000 RPM GE Actuator
ECM
Injection Quantity Fuel Injection
37mg/stroke 2.8 Volt
APS
Accel. Position CSP
50% Control Sleeve
Feedback Position Check
Control Logic 11

Injection Timing Controls

Np Sensor when CPS is failed

Pump speed
Eng. speed
ECM TCV
CPS
Injection Timing Duty(%) Control

ECM TPS
Injection Quantity Injection
Feedback Timing Check
Components Description 12

Injection Pump(Mechanical)
Governor Spring

Flyweight Idle Spring

Full Load Adjusting Screw

Control Lever
Control Lever Shaft Tension Lever
Governor Leve Assembly

Regulating Valve Fuel Cut Solenoid

Plunger

Outlet Hole

Drive Shaft
Feed Pump Delivery Valve
Driving Gear Control Sleeve
Timer
Plunger Spring
Cross Coupling
Cam Disc
 Components Description 13

Injection Pump(Electronic)
Governor
Fuel Cut Electronic
Solenoid

Np Sensor

Timer Control Valve.

Components Description 14

GE(Governor Electric) Actuator

Magnet Filter
Components Description 15

TCV (Timer Control Valve)

Duty Ratio = to/T X 100 (%)

Duty Ratio = 100% Æ 0%

T (Advanced) (Retarded)
Components Description 16

TPS (Timer Position Sensor)

Retarded Advanced
Components Description 17

Np Sensor

Np Sensor
Engine Control Module 18

ECM Terminal Layout

Terminal Signal Connected to

1 GE + GE
2 GE - GE
3 Power Power Relay
4 Start Switch Ignition Switch
5 A/C Switch A/C Switch
6 Neutral Switch (P, N) Inhibitor Switch(for A/T), Neutral Switch (for M/T)
8 Idle Switch Accelerator Pedal
10 Immobilizer Switch 01 IG 1 (with immobilizer), Open(without immobilizer)
11 A/C Load Detection A/C Compressor Relay
12 Ground (Power) -
13 TCV Signal TCV
Engine Control Module 19

ECM Terminal Layout

Terminal Signal Connected to

14 GE + GE
15 GE - GE
16 Power Power Relay
17 TW Signal Water Temperature and Gauge Unit
18 TF Signal Fuel Temperature Sensor
19 TA Signal Boost Pressure and Temperature Sensor
20 Qadj Resistance Signal Qadj. Resistance
21 Ignition Switch Ignition Switch
23 Glow Check Glow Plug and Glow Relay
24 Immobilizer Switch 02 Open(with immobilizer), IG 1 (without immobilizer)
25 GND (Power) -
Engine Control Module 20

ECM Terminal Layout

Terminal Signal Connected to

26 FCV Signal Fuel Cut Solenoid Valve
29 TDC Signal Camshaft Sensor
30 Np Signal Np Sensor
31 Torque Control (PWM) TCU (A/T Only)
32 Vref Accelerator Pedal Sensor
33 Vref Boost Pressure and Temperature Sensor
34 Boost Pressure Signal Boost Pressure and Temperature Sensor
35 Intercooler Fan Relay Intercooler Fan Relay
36 Tach Out (PWM) TCU (A/T Only)
37 GND Camshaft Sensor
38 GND Np Sensor
Engine Control Module 21

ECM Terminal Layout

Terminal Signal Connected to

39 GND Accelerator Pedal Sensor
40 Accelerator Pedal Sensor Signal Accelerator Pedal Sensor
41 GND (Analog) Water Temperature and Gauge Unit
42 GND (Analog) Water Temperature and Gauge Unit
43 OSC + Control Sleeve Position Sensor
44 MDL Control Sleeve Position Sensor
45 OSC - Control Sleeve Position Sensor
46 TPS (OSC +) Timer Position Sensor
47 AT/MT Switch Open (for AT), IG 1 (for MT)
49 OSC + Control Sleeve Position Sensor
50 MDL Control Sleeve Position Sensor
Engine Control Module 22

ECM Terminal Layout

Terminal Signal Connected to

51 OSC - Control Sleeve Sensor
52 TPS (MDL) Timer Position Sensor
53 TPS (OSC -) Timer Position Sensor
54 L – Line Diagnostic Tool (Scan Tool)
55 Glow Relay Glow Relay
57 TW Out TCU (AT only)
58 EGR 1 EGR 1 (Duty)
59 A/C Fan Relay A/C Fan Relay
61 K – Line Diagnostic Tool (Scan Tool)
62 Diagnosis Lamp Engine Check Lamp
63 Glow Lamp Glow Lamp
Engine Control Module 23

ECM Terminal Layout

Terminal Signal Connected to

64 Signal Power Relay
65 GND (Signal) -
68 A/C Compressor Relay A/C Compressor Relay
69 Accel. Out (PWM) TCU (AT only)
71 VSP Signal Vehicle Speed Sensor
72 EGR 2 EGR 2 (On-Off)
73 Main Relay Power Relay
75 Signal Power Relay
76 GND (Signal) -
Troubleshooting 24

TCV (Timer Control Valve)

F.I.P
Connector

No.9 TCV-
TCV

No.5 TCV+

Specification
No.5 ~ No.9: 11±0.7 Ω

Connection with Others

No.5 IG. Key(B+)
No.9 ECM Pin No. 13

At idle At acceleration
Troubleshooting 25

TPS (Timer Position Sensor)

No.3 MDL
F.I.P
Connector

No.2 OSC+

No.1 OSC-

TCV
Specification
No.2 ~ No.3, No.1 ~ No.3: 82±5.7 Ω

Connection with Others

No.1 ECM Pin No. 53
No.2 ECM Pin No. 46
No.3 ECM Pin No. 52
ECM Pin No. 52, 46 at idle ECM Pin No. 52, 53 at idle
Troubleshooting 26

Np Sensor

F.I.P
Connector

No.2
ECM GND

No.3 Signal

Specification
No.2 ~ No.3: 1.65±0.15 kΩ

Connection with Others

No.2 ECM Pin No. 38 GND
No.3 ECM Pin No. 30 Signal

Np Signal at idle Np Signal with CKP Sensor at idle

 Troubleshooting 27

Q Compensation Resistance

Q Adjustment Q Comp.
Resistance Resistance Number Part No.
(kΩ)
No.1(0.18) 945 146649-4500
No.2(0.30) 946 146649-4600
No.3(0.43) 947 146649-4700
No.4(0.62) 948 146649-4800
No.5(0.82) 949 146649-4900
No.6(1.10) 950 146649-5000
No.7(1.50) 951 146649-5100
F.I.P No.8 (2.0) 952 146649--5200
Connector No.9(2.70) 953 146649-5300
No.10(3.9) 954 146649-5400
No.2 GND
No.11(5.6) 955 146649-5500
No.12(8.2) 956 146649-5600
No.13(150.) 957 146649-5700
No.3 Sig
Troubleshooting 28

CSP (Control Sleeve Position) Sensor

Troubleshooting 29

CSP (Control Sleeve Position) Sensor

No.1 OSC -

F.I.P
Connector
No.8 OSC
MDL

No.12 OSC -

No.4 OSC +
Specification
No.4 ~ No.8, No.12 ~ No. 8: 5.9 ±0.3 Ω

Connection with ECM

No.4 ECM Pin No. 43, 49
No.8 ECM Pin No. 44, 50
No.12 ECM Pin No.45
ECM Pin No. 43, 44 at idle ECM Pin No. 43, 45 at idle
No. 1 ECM Pin Nol 51
Troubleshooting 30

TF (Temperature Fuel) Sensor

F.I.P
Connector

No.7 Signal

No.11 GND

Specification
No.7 ~ No.11: 2±0.1kΩ at 25℃ ECM Pin No. 18 at
Connection with ECM normal operating
Temperature
No.7 ECM Pin No. 18
No.11 Wiring harness GND
Troubleshooting 31

WTS (Water Temperature Sensor)

Specification

Temp.(℃) Resistance(kΩ) Voltage(V)

-20 16 4.3
0 5.9 3.4
20 2.5 2.4
40 1.2 1.5
60 0.6 0.9
80 0.3 0.5
100 0.2 0.3

3 2 1
ECM Pin No. 17 at
Connection with ECM normal operating
Temperature
No.2 to Cluster
No.1 ECM Pin No. 17
No.3 ECM Pin No. 42 (GND)
Troubleshooting 32

BPS (Booster Pressure Sensor) / TA (Intake Air Temperature)

Sensor
TA Sensor Specification
Temp.(℃) Resistance(kΩ) Voltage(V)
-20 16 4.3
0 5.9 3.4
20 2.5 2.4
40 1.2 1.5
60 0.6 0.9
80 0.3 0.5
100 0.2 0.3

Connection with ECM

No.1 ECM Pin No. 41 GND
4 3 2 1
No.2 ECM Pin No. 19 TA Signal
No.3 ECM Pin No. 33 Reference Voltage 5V
No.4 ECM Pin No. 34 BPS Signal
Troubleshooting 33

BPS (Booster Pressure Sensor) / TA (Intake Air Temperature)

Sensor

ECM Pin No. 34 BPS Signal at idle ECM Pin No. 34 BPS Signal at 4200rpm

ECM Pin No. 34 BPS Signal at acceleration ECM Pin No. 19 TA Sensor Signal
from idle to 4200rpm
Troubleshooting 34

APS (Accelerator Pedal Sensor)

Connection with ECM
No.1 ECM Pin No.39 GND
6 5 4
No.2 ECM Pin No.40 APS Sig.
3 2 1
No.3 ECM Pin No.32 (Power Supply)
No.4 ECM Pin No.32 Idle Switch APS Side Connector
No.5 None
No.6 Ground Idle Switch ON Accelerator Pedal Sensor

ECM Pin No. 8 at acceleration ECM Pin No. 40 from idle to Max.
Troubleshooting 35

APS (Accelerator Pedal Sensor)

APS output signal failed, Idle Switch good, At

Good condition (Max. Throttle) Max. Throttle
ECM increases RPM slowly to 30% (4000rpm)
Troubleshooting 36

CPS (Crankshaft Position Sensor)

CPS

1mm

3 2 1

Connection with ECM

No.1 Shield GND
No.2 ECM Pin No. 37 GND
No.3 ECM Pin No. 29 Signal ECM Pin No. 29 at idle CPS signal with Np signal at idle
Troubleshooting 37

Fuel Cut valve

No.1 FCV

F.I.P
Connector

No.2
ECM GND

No.3 Np Signal

FC Valve

Connection with ECM

No.1 ECM Pin No.26 Signal
Troubleshooting 38

EGR (Exhausted Gas Recirculation) Control Valve

EGR Control Solenoid Valve 1

(Duty Control)

Connection with ECM

1 2
Pin No. 2 of EGR Sol. Valve No.1 ECM Pin No.58 Signal
Pin No. 1 of EGR Sol. Valve No.1 Main Relay B+ EGR Control Solenoid Valve 2
Pin No. 2 of EGR Sol. Valve No.2 ECM Pin No.72 Signal (On-OFF Control)
Pin No. 1 of EGR Sol. Valve No.2 Main Relay B+
Troubleshooting 39

EGR (Exhausted Gas Recirculation) Control Valve

Waveform

ECM Pin No. 58 at idle ECM Pin No.58 at acceleration ECM Pin No. 72 at acceleration
Troubleshooting 40

Intercooler Fan Motor

Connection with ECM

I/C Fan Motor Relay No.2 ECM Pin No.35

Operational Condition (AND)

♦ Vehicle speed : 60km/h or less

♦ Intake air temperature : 58℃ or higher
♦ Engine speed : 550 rpm or more
Troubleshooting 41

Glow System

Preheating Post heating

Coolant Coolant
Heating Time (sec) Heating Time (sec)
Temperature Temperature

60 ℃ 2 60 ℃ 3

- 15 ℃ 8 0℃ 3

- 20 ℃ 10 - 10 ℃ 3

- 25 ℃ 15 - 20 ℃ 5

- 40 ℃ 24 - 40 ℃ 5
Troubleshooting 42

Others

Main relay control

ECM controls Main relay to provide the B+ voltage to actuators like EGR Sol.
Valves, Grow Plug and A/C fan relay etc.

Lamps
ECM controls Engine check lamp and Glow lamp

Connection with ECM

Main Relay No.4 ECM Pin No.73

Engine check lamp ECM Pin No.62

Glow lamp ECM Pin No.63

A/C Fan Motor Relay ECM Pin No.59

A/C Comp. Relay ECM Pin No.68

Troubleshooting 43

Case Study
Diag.
DTC Item Cause of Trouble Symptom
Lamp

P0320 Np Sensor
1. Np/TDC output is lower than threshold level If one of sensor has
2. Open or short sensor coil failed, normal
3. Noise operation is possible
OFF
P0335 TDC Sensor 4. Bad connection If both sensors are
5. Open or short wire problem, engine will
6. Clearance is too big stop.

Acceleration
P0121 Pedal Positon ON 1. Open or short sensor harness
Sensor 2. Bad connection Idle mode driving,
3. Open or short wire Limp Home
Accel Sensor 4. Abnormal output value
P0120 OFF
Output

Accel Sensor Normal operation is

P0120 OFF 1. Abnormal output value
Learning possible
Troubleshooting 44

Case Study
Diag.
DTC Item Cause of Trouble Symptom
Lamp
1. Open or short sensor harness
Water 1. Smoke may
2. Bad connection
P0115 Temperature ON comes out
Sensor 3. Open or short wire
2. Idle rpm increase
4. Abnormal output value

Water 1. Lack of coolant Vehicle speed is

- Temperature ON 2. Malfunction of thermostat decreased by
Sensor 3. Defective cooling system overheating

1. Open or short sensor harness

Fuel 2. Bad connection Normal operation is
P0180 Temperature OFF
3. Open or short wire possible
Sensor
4. Abnormal output value

1. Open or short sensor harness

Itake Air 2. Bad connection Normal operation is
P0110 OFF
Temperature 3. Open or short wire possible
4. Abnormal output value
Troubleshooting 45

Case Study
Diag.
DTC Item Cause of Trouble Symptom
Lamp
1. Open or short sensor harness
Boost Pressure 2. Bad connection
P1116 ON
Sensor 3. Open or short wire
4. Abnormal output value No acceleration
1. Too much fuel injection (Low speed operation)
2. Retarded injection timing
P1122 Over Boost ON
3. Disabled wastgate actuator
4. Disabled turbocharger

1. Smoke
1. Open or short sensor harness
2. Abnormal
2. Bad connection
P1123 TPS OFF acceleration
3. Open or short wire
3. Unstalbe idle RPM
4. Abnormal output value
4. Noise
1. Bad adjustment of timer piston position
P1123 TPS Learning OFF 2. EEPROM Error -
3. TCV Error
Troubleshooting 46

Case Study
DTC Item Diag. Lamp Cause of Trouble Symptom
1.Open or short sensor
coil
(Abnormal Sensor Output)
P1127 CSP Rareshort ON Engine stops
2.Bad connection of
connector
3.Open or short wire
1.CSP SENSOR ERROR
2.Abnormal GE’s Yoke/Rotor
operation
P1120 GE Servo ON Engine stops
3.Fuel temperature is low
and has high viscosity
4.Open or short wire
1.TPS SENSOR ERROR
2.Timer piston’s operation
error 1.Too much smoke
P1135 IT Servo OFF 3.Fuel has high viscosity and 2.Abnormal acceleration
in low temperature. 3.Unstable IDLE RPM
4.TCV ERROR
5.Open or short wire
Troubleshooting 47

Case Study
DTC Item Diag. Lamp Cause of Trouble Symptom
1.SMOKE increases
2.Abnormal acceleration
P0605 EEPROM OFF 1.ECU ERROR
3.Starting in impossible
for IMMOBI. Vehicle

1.Open or short sensor 1.Power and

harness acceleration is bad in
Barometric low zone from sea-
2.Bad connection of
P0105 Pressure OFF level
connector
Sensor 2.Too much smoke in
3.Open or short wire
high zone from sea-
4.Abnormal sensor output level

1.EEPROM ERROR Normal operation is

possible when EEPROM
2.Bad connection of
is normal condition.
Q Adjustment - connector
P1131 OFF Too much smoke
Resistance 3.Open or short wire
/abnormal acceleration
4.Open or short wire in happens when EEPROM
resistor is not normal condition
Troubleshooting 48

Case Study
DTC Item Diag. Lamp Cause of Trouble Symptom

1.Abnormal GLOW RELAY

1.Starting is not possible
2.Bad connection of
Blink in low temperature
P1324 Glow Relay connector
(75times/min) 2.Increase of starting
3.Open or short wire
time
4.Voltage overflow

1.Communication error
2.Bad connection of
P0600 Immobilizer OFF Starting is impossible
connector
3.Open or short wire

1.Open of short FCV wire

1.Engine stops
P1621 FCV Short ON 2.Bad connection of
2.Starting is impossible
connector

1.ECU circuit ERROR

Abnormal sensor output
Accel Sensor 2.Open or short wire
P1525 OFF / Power with ACCEL
Ref. Voltage 3.Bad connection of SENSOR ERROR
connector
Troubleshooting 49

Case Study
DTC Item Diag. Lamp Cause of Trouble Symptom
1.ECU circuit ERROR
Abnormal sensor output
Boost Sensor 2.Open or short wire
P1525 OFF / Power with BOOST
Ref. Voltage 3.Bad connection of SENSOR ERROR
connector

P1613 A/D Conversion OFF 1.ECU circuit ERROR -

1.VSP SENSOR ERROR

SHOCK occurs at
2.Open or short wire
P0500 VSP Sensor OFF acceleration or
3.Bad connection of deceleration.
connector

1.Open or short wire

Battery
P1522 ON 2.Abnormal BATTERY -
Voltage
charging
Injection Timing Adjustment 50

Basic Injection Timing

1. Engine stop
2. Turn the crankshaft to place in No.1
Cylinder at top dead center on
compression stroke
3. Loosen injection pipe
4. Loosen injection mounting bolts and nuts
5. Remove timing check plug from injection
pump head

6. Attach the special tool and a dial

gauge
7. Turn crankshaft to such a position
that the notch on pulley is at
approximately 30° before top
dead center. Then , set dial
indicator to zero.
Injection Timing Adjustment 51

Basic Injection Timing

8. Slightly turn crankshaft clockwise and
counterclockwise to make sure that
dial indicator pointer does not deviate
from zero position.
9. Turn the crankshaft in the normal
direction and position the notch of
crankshaft pulley at 7 ° ATDC.

10. If the dial indicator does not indicate the

specified value.
Tilt the injection pump body to the right
or left until the indicator does indicate the
standard value.
11. Tighten mounting bolt of injection bolts
and nuts.
12. Remove special tool and dial gauge
13. Install timing check plug with new
copper gasket